Cassettes for systems which feed, count and dispense discrete objects

ABSTRACT

A high capacity cassette for an object counting and dispensing system includes a substantially horizontal base including an exit hole, a peripheral wall about the base and having an internal periphery, the base and the peripheral wall defining a reservoir adapted to store a plurality of the discrete objects, and a structure about the internal periphery which feeds the discrete objects single file toward said exit hole.

This application is a continuation-in-part of U.S. Ser. Nos. 09/871,531now Pub. No. 20020/79623, U.S. Ser. No. 09/871,532 now Pub. No.6497339/20020/79619, and U.S. Ser. No. 09/871,533 now Pub. No.20020/79621, each of which was filed on May 31, 2001, and all of whichare hereby incorporated by reference herein in their entireties.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates broadly to feeding, counting and dispensingapparatus. More particularly, this invention relates to feeding andcounting apparatus which use vibration to control the flow of discreteitems, such as tablets, capsules or caplets being fed and counted.

2. State of the Art

In retail, hospital, and mail order medication dispensing, a largenumber of different prescriptions of single dose medications, such astablets, must be filled. (Hereinafter, for purposes of brevity,reference to “tablets” should be understood for purposes herein as beinggeneric to tablets, capsules, caplets and any other solid dosemedication). For prescriptions requiring small quantities of amedication, the prescription is often filled by hand; that is, a bulkcontainer containing the prescription medication is removed from a shelfand opened. A quantity of the medication is poured into a tray and themedication tablets are counted by a pharmacist and then dispensed into apatient prescription bottle. The remainder of the medication in the trayis returned to the bulk container, the container is closed, and thenreplaced on the shelf.

Larger quantity prescriptions are often filled with the aid of acounting apparatus intended to more rapidly count different quantitiesof different tablets successively. For example, a prescription forninety tablets of 10 mg Claritin® may need to be filled after aprescription for sixty tablets of 400 mg Motrin®. Generally, there aretwo types of counting apparatus available for dispensing prescriptionmedication from bulk containers of such medications: a preset counterand a pour-through counter.

With a preset counter, the pharmacist obtains a bulk container of aprescription medication from a shelf and then pours from the container aquantity of tablets into a hopper of the counting apparatus. Thepharmacist then sets the counting apparatus to the number of tablets tobe counted, e.g., ninety. Assuming at least the required number oftablets for the prescription has been poured into the hopper, thepharmacist waits while the counting apparatus counts the required numberof tablets and dispenses the tablets into a patient prescription bottle.The excess tablets are discharged back into the bulk container, which isthen replaced on the shelf. It has been found that the time taken todischarge the excess tablets can be equal to or greater than the timerequired to count the prescription. For that reason, the pour-throughcounter has proved more popular.

A pour-through counter does not include a hopper that temporarily storesthe medication. Rather, the pharmacist pours tablets from a bulkcontainer directly into a funnel which drops the tablets past a counterand dispenses them into a patient bottle. The pharmacist pours until thedigital readout of the counter apparatus displays the required number oftablets, and then stops. As such, there is usually no excess. However,should an extra tablet or so fall into the funnel, the readout clearlyindicates the extra number, and the excess can easily be removed by thepharmacist and returned to the storage container.

Both the preset and pour-through counter systems have a common drawback.Each prescription medication must be obtained from a bulk storagecontainer located in stock, which must be opened prior to use and closedafter use. In order to minimize the time taken to dispense aprescription, counter manufacturers have provided “cassette counters”for retail, hospital, and mail order pharmacies. Each cassette isdesigned for a specific size and shape capsule, tablet, or caplet. Thecassettes are prefilled by the pharmacist with bulk quantities of theappropriate prescription drugs, and are used to store bulk quantitiesrather than using the container supplied by the manufacturer. Theprescription medication is then dispensed directly from the cassette.The use of cassettes eliminates the time needed to open themanufacturer's original container, the time needed to return excesstablets to the container, and the time needed to close the container.Unfortunately, cassette counters are slow and prone to breaking tablets.Furthermore, when cassettes jam, as they often do, they are difficult tounclog. Often tablets spill uncontrollably from the cassette duringattempts to unclog a jam. Further, since the cassettes used in existingcassette systems are specific to the tablet being dispensed, each time apharmacist wants to count a new drug, a new cassette designed for thatspecific medication must be obtained. In addition, some prescriptionsare filled infrequently and it is not economically feasible or practicalto have a dedicated cassette for every solid dose medication in thepharmacy.

SUMMARY OF THE INVENTION

It is therefore an object of the invention to provide a system forcounting and dispensing discrete objects such as tablets, capsules andthe like which permits storing discrete objects in a manner in which theobjects may be quickly dispensed.

It is another object of the invention to provide a counting anddispensing system which uses cassettes which are not customized to aparticular tablet or capsule.

It is a further object of the invention to provide a counting anddispensing system which uses cassettes which are relatively inexpensiveto manufacture.

It is an additional object of the invention to provide a counting anddispensing system which is not subject to jamming by discrete objectsbeing counted.

Another object of the invention is to provide a counting and dispensingsystem which provides rapid counting of the discrete objects.

A further object of the invention is to provide a counting anddispensing system which can also be used without a cassette.

An additional object of the invention to provide a counting anddispensing system which has the benefits of two different modes ofoperation, as a pour through counter, as well as a preset counter.

Yet a further object of the invention is to provide a counting anddispensing system which can also be used with a bowl feeder.

Yet another object of the invention is to provide a counting anddispensing system which is adapted for rapid exchange of cassettes andbowl feeders.

It is yet an additional object of the invention to provide a countingand dispensing system which functions with high reliability.

In accord with these objects, which will be discussed in detail below,an object counting and dispensing system is provided which includes avibration system which substantially circularly vibrates in a horizontalcircular plane, a mounting assembly for coupling a cassette to thevibration system, a chute configured to receive discrete objects fromeither the cassette or a funnel and dispense the objects to a patientbottle, and an object sensing system which senses and counts objects fedinto the chute.

Each cassette includes a base and a stepped side wall which togetherdefine a central open reservoir portion and at least one substantiallyplanar covered tray portion surrounding the reservoir portion. A lid isremovably coupled over the reservoir portion. The reservoir portion isadapted to store tablets and feed the tablets through a path into thetray portion. The tray portion has a peripheral exit and guides the fedtablets toward the exit when the cassette is vibrated by the vibrationsystem. The tray portion optionally includes a peripheral track whichfacilitates the guidance of tablets having non-flat surfaces toward theexit. A leaf spring gate closes the exit and is automatically opened bya permanent magnet attached to the tip of a solenoid when the cassetteis attached to the mounting assembly, and closed when the cassette isremoved therefrom. When the last tablet in a batch has been counted, themagnet is retracted and the leaf spring closes the exit of the cassette.The leaf spring also closes the cassette when the cassette is removedfrom the mounting assembly and moved away from the magnet. Each cassetteincludes a lower metal portion at which the cassette is mounted to themounting assembly. Cassettes are mounted to the mounting assembly in amanner which permits rapid and secure coupling and decoupling. Preferredcoupling means include an electromagnetic coupling system.

Each cassette is able to feed and guide a range of sizes and shapes oftablets toward the exit. As such, only a few standard sizes of cassettesare needed to accommodate a wide range of discrete objects for which thecounter is primarily adapted: tablets, capsules, caplets, etc. When usedwith the cassette, the system functions as a preset counter wherein thecounter is preset to count a desired number of tablets, and the counterthen feeds and counts the exact number of tablets from the cassette.

Additional high capacity cassettes are also provided which include abase and a side wall which together define a reservoir portion, an exitfrom the reservoir, and a peripheral structure adapted to direct objectssingle file toward the exit.

As briefly discussed above, according to another aspect of theinvention, the system can be used without the cassette and operate as apour-through counter in which tablets are poured into the funnel.

In addition, a universal bowl feeder can be attached to the mountingassembly, preferably in the same manner as the cassettes. The bowlfeeder can accommodate prescriptions which are not provided with theirown cassette and for which it is desired to preset the number of tabletsto be counted.

Additional objects and advantages of the invention will become apparentto the skilled in the art upon reference to the detailed descriptiontaken in conjunction with the provided figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a system for feeding, counting, anddispensing discrete objects according to the invention, shown with acassette attached thereto;

FIG. 2 is a plan view of the system for feeding, counting, anddispensing objects according to the invention, shown with a cassetteattached thereto;

FIG. 3 is a section view across line 3—3 in FIG. 2;

FIG. 4 is a section view across line 4—4 in FIG. 2;

FIG. 5 is a perspective view of the assembly of a vibration system, amounting assembly, a chute and a spout, and an object sensing system,and a cassette attached to the mounting assembly, the cassette having agate in an open position;

FIG. 6 is an exploded perspective view showing the spout removed fromthe housing of the system according to the invention;

FIG. 7 is a perspective view of a cassette according to the inventionwith a lid enclosing the reservoir of the cassette;

FIG. 8 is a section view across line 8—8 in FIG. 7;

FIG. 9 is a perspective view of a cassette according to the inventionwithout a lid enclosing the reservoir of the cassette;

FIG. 10 is a plan view of a base portion of the cassette according tothe invention;

FIG. 11 is a perspective view of the assembly of a vibration system, amounting assembly, a chute and a spout, and an object sensing system,and a cassette attached to the mounting assembly, the cassette having agate in an open position;

FIG. 12 is a bottom perspective view of the mounting system and thevibration system, the mounting system shown with a cassette coupledthereto;

FIG. 13 is a top perspective view of the mounting system and thevibration system;

FIG. 14 is a plan view of the base portion of the cassette provided withcapsules and illustrating the movement of capsules thereon;

FIG. 15 is a section view of a multi-tray cassette according to theinvention;

FIG. 16 is a plan view of a bottom tray of the multi-tray cassette ofFIG. 15;

FIG. 17 is a plan view of a top tray of the multi-tray cassette of FIG.15;

FIG. 18 is a perspective section view of another cassette according tothe invention;

FIG. 19 is a plan view of the cassette of FIG. 18;

FIG. 20 is a section view across line 20—20 in FIG. 19;

FIG. 21 is a top perspective section view of yet another cassetteaccording to the invention;

FIG. 22 is a perspective section view of the cassette of FIG. 21.

FIG. 23 is a plan view of the cassette of FIG. 21;

FIG. 24 is a section view across line 24—24 in FIG. 23;

FIG. 25 is an exploded perspective view of the system for feeding,counting, and dispensing discrete objects according to the invention,shown with a funnel adapted to be provided in alignment with the chuteof the system;

FIG. 26 is a plan view of the system for feeding, counting, anddispensing objects according to the invention, shown with a funnelattached in alignment with the chute; and

FIG. 27 is a perspective view of a universal vibratory bowl feederattached to the mounting and vibratory assemblies according to theinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning now to FIGS. 1 through 5, according to a preferred embodiment ofthe invention, an object counting, feeding, and dispensing system 10includes a vibration system 12 which substantially circularly vibratesin a horizontal plane, a mounting assembly 14, described in detailbelow, which secures a cassette 16 to the vibration system in a mannerin which the cassette may be rapidly removed such that another cassettecan be rapidly secured to the mounting assembly, a chute 18 oriented toreceive discrete objects from a cassette 16 and feed the objects to abottle or container located at an exit spout 21 beneath the chute, andan object counting system 22 which through windows 23 a, 23 b senses andcounts objects passing within the chute 18. Hereinafter, the term‘tablets’ is used interchangeably with ‘objects’, unless the contextdictates otherwise.

The vibration system 12, mounting assembly 14, chute 18, and objectcounting system 22 are provided in a housing 24. The housing 24 isprovided with a user display 26, and an input panel 28, as well as amicroprocessor 30. The display 26 indicates the number of tabletscounted, and is coupled via the microprocessor 30 to the object countingsystem 22. The input panel 28 permits the user to input a number oftablets which the system is to feed, count and dispense to a bottle. Apower supply 34 is electrically coupled to the vibration system 12, themounting assembly 14, the object counting system 22, the display 26 andinput panel 28, and the microprocessor 30. The object counting system 22is preferably an optical system which uses an optical sensor array, suchas that disclosed in co-owned U.S. Pat. No. 5,768,327, which is herebyincorporated by reference herein in its entirety. The optical sensorarray of U.S. Pat. No. 5,768,327 includes an orthogonal arrangement oftwo discrete optical sensors which together sense objects in threedimensions. This sensor arrangement is adapted to sense multiple objectssimultaneously falling passed the sensors. Alternatively, the countingsystem may include any other counter for counting discrete objects whichis known in the art. As shown in FIG. 6, the spout 21 includes an upperlip 21 a at which the spout is preferably removably mounted on twoslides 110, 112 which holds the spout beneath the chute, but permitsremoval. The spout is also preferably provided with a gate 114 whichprevents dispensing from the spout until lifted, thereby preventing thetablets from spilling from the spout until the user is prepared with abottle at the exit spout. The spout 21 may be slidably removed from theslides 110, 112 for cleaning. In addition, the spout can be removed fortransfer of the contents of the spout to another location (with the gatein the closed position), and then inverted to pour the spout contentsfrom the lip end of the spout.

Referring to FIGS. 1 and 2, the top of the housing 24 preferablyincludes an upper deck 120, a lower deck 122, and a generally verticalwall 124 at the junction thereof. The upper deck 120 includes acircular-portion recess 128 which extends through the wall 124 and whichis sized and shaped to receive a preferably substantial portion of acassette 16. The recess 128 is preferably approximately 270° incurvature. The mounting assembly 14 is accessible at the recess 128. Therecess 128 also includes a sensor 129 (FIGS. 25 and 26) which senseswhen a cassette is positioned in the recess. The chute 18 has anentrance 130 on the lower deck 122 which is preferably provided with ashield 132 which partially covers the entrance of the chute. The shield132 has several functions: it functions as a light shield to preventstray light from interfering with the optical sensory array of theobject counting system 22, it functions as a object shield to preventstray objects from falling into the chute and being counted, and it mayfunction as a placement guide to facilitate the rapid placement of acassette on the mounting assembly 14. While the shield 132 is preferablya discrete element which may be positioned in the chute, it mayalternatively be formed as part of the cassette to provide some or allthe same functionality. As such, when the cassette is provided on themounting assembly, the shield initially would function as a guide tofacilitate the placement of a cassette on the mounting assembly, andthen shield stray light from the optical sensory array and prevent strayobjects from falling into the chute.

Turning now to FIGS. 7 through 10, each cassette 16 includes arelatively thin preferably plastic base 40 and a preferably plastic topelement comprised of a wall 42 and an annular shelf 43 fixedly coupledto the base such that the base and top element together define a centralreservoir portion 44 and a peripheral covered tray portion 46. The base40 preferably includes a peripheral wall 48, and a reservoir wall 50concentric with the peripheral wall and having an opening 52. An entryguide 56 is obliquely angled relative to the reservoir wall 50 at theopening 52 and defines a narrow 53 between the end of the entry guideand the peripheral wall which serves as an entry to track area 54. Thebase 40 also includes an exit hole 58 adjacent the peripheral wall 48substantially 270° counterclockwise relative to the entry guide 56, andan exit guide 60 located relative to the peripheral wall 48 such thattablets traveling between the peripheral wall 48 and the exit guide 60are directed in a single file to the exit hole 58. The base 40preferably includes a return guide 62 which facilitates movement oftablets which have not entered the exit guide 60 in the counterclockwisedirection back toward the entry guide.

In the preferred embodiment, the opening 52 is defined between the entryguide 56 and a free end 64 of the return guide 62. Optionally, a shallowconcavely curved or sloped channel 66 having a width for guiding asingle tablet or capsule is formed in the base 40 adjacent a portion ofthe peripheral wall 48 from the location of the entry guide 60counterclockwise to the exit hole 58. The width of channel is preferablybetween 0.5-1.5 times the width of the range of tablets or capsules forwhich the cassette is designed. The base 40 preferably also includes acentral circular hole 68, and a metal plate 70 on the base over the hole68 (FIGS. 8 and 9). The plate 70 includes a hole 71, and a post 72 iscoupled in the hole 71 and extends vertically upwards therefrom. Theupper end 74 of the post is threaded. A lid 76 including a central hole78 is provided on the top element 42 such that the upper end 74 of thepost extends through the hole 78. A knob 80 is threaded onto the post inorder to secure the lid 76 on the top element 42 and to enclose thereservoir 44 (FIGS. 7 and 8).

Preferably the height of each of the peripheral wall 48, the reservoirwall 50, and the guides 56, 60 and 62 is the same, height H (FIG. 8).The shelf 43 rests on the walls 48 and 50 and guides 56, 60 and 62 tosubstantially enclose the tray portion 46 to provide the tray portionwith a height H. The height H is preferably substantially 1.2 to 1.8times the height of a tablet (across the diameter of cylindricalcapsules and caplets, or transverse to the flattest surface of a tablet)which is to be stored in and fed from the cassette. In addition, theopening 52 is preferably approximately three to eight tablets in size(across the diameter of cylindrical capsules and caplets or the flattestsurface of a tablet). Furthermore, the narrows 53 is preferablyapproximately two to four tablets in size (across the diameter ofcylindrical capsules and caplets or the flattest surface of a tablet).As such, a single cassette is adapted to feed and guide a range of sizesand shapes of discrete objects toward the exit. Only a few standardcassettes sizes are thereby needed to accommodate all discrete objectsfor which the counter is primarily adapted: tablets, capsules, caplets,etc. In addition, the manufacture of the cassettes is relativelyinexpensive, as the primary material of manufacture is plastic, and thecassette for an individual prescription does not need to be custommanufactured.

Referring back to FIG. 5, the cassette 16 is provided with a metal leafspring 81 having an upturned gate portion 82 extending into and blockingthe exit hole 58 of the cassette. A means, e.g., a solenoid 83, isprovided in the housing for automatically opening the gate andpermitting the tablets to exit the exit hole 58 of the cassette 16. Thesolenoid 83 is mounted on a mounting bracket 99 and has a shaft 83 aextending thereabove. The solenoid shaft 83 a preferably does notcontact the gate to open the gate. Rather, a magnet 83 b is provided atthe end of the shaft 83 a. When the solenoid 83 is actuated, the magnet83 b is moved closer to the leaf spring 81 causing the leaf spring todeflect toward the magnet 83 b and pull the gate portion 82 from theexit hole 58 to permit the release of tablets in the cassette (FIG. 11).Deactivation of the solenoid 83 moves the magnet 83 b further from theleaf spring 81 such that the bias of the leaf spring overcomes the forceof the magnet 83 b, and the exit hole 58 is again closed by the gateportion 82 (FIG. 5). Other magnetic, mechanical or electromechanicalelements or assemblies may alternatively be used to close and open theexit hole of the cassette.

Referring to FIGS. 1 through 3 and 5, the cassette 16 preferably alsoincludes two alignment posts 84, 85. The posts 84, 85 are preferablyequally spaced apart about the exit hole 58. The posts 84, 85 arepreferably nondiametrically located, and most preferably separated byapproximately 120°. The posts are spaced to align the cassette with thewall 124 on the housing (but preferably not contact the wall) when thecassette 16 is placed on the upper deck 120 (FIGS. 1 and 2). Thisensures alignment of the exit hole 58 over the chute entrance 130.

Cassettes 16 are mounted to the mounting assembly 14 in a manner whichpermits rapid and secure coupling and decoupling. Preferred couplingmeans include electromagnetic coupling and power-driven clampingsystems. Referring to FIGS. 12 and 13, with respect to anelectromagnetic coupling, the mounting assembly 14 includes a base 86provided with a preferably cylindrical electromagnet 88 sized to fitsnugly at least partially within the hole 68 in the bottom of thecassette and provided adjacent the metal plate 70. The cassette 16 isprovided over the electromagnet 88, and the electromagnet is activatedto cause a secure coupling of the cassette thereto. Conversely,deactivation of the electromagnet permits rapid decoupling of thecassette from the mounting assembly. The base 86 preferably includes aplurality of resilient ball plungers 90 adapted to force the bottom ofthe cassette 16 from its snug fitting over the electromagnet 88 when theelectromagnetic is deactivated. The base 86 is also coupled to twobrackets 92 on opposite sides of the base adapted to couple the base tothe vibration system 12.

Still referring to FIGS. 12 and 13, the vibration system 12 includes twoshaker elements (electromechanical vibrators known in the art) 94 whichare coupled to opposite side walls 96 of a rigid U-shaped block 98. Inturn, the brackets 92 of the mounting assembly 14 are coupled betweenthe shaker elements 94. The shaker elements 94 are adapted to provide ahorizontal circular vibratory motion in the feed direction (FIG. 10) tothe mounting assembly and consequently to a cassette rigidly mounted onthe mounting assembly. The inertial block 98 is coupled by rubber shockmounts 100 to a support 102 within the housing. The shock mounts 100substantially prevent vibratory energy from being transferred to thehousing 24.

In use, the reservoirs of a plurality of cassettes in a pharmacy settingare each provided with the tablets of a different prescription medicine.If it is then desired to count a fixed or predetermined number (e.g.,one hundred) of capsules 104 of a particular prescription into a bottle,the cassette 16 containing the particular prescription is provided onthe mounting assembly 14 of the system. This is particularly done byproviding the cassette in the recess 128 in an orientation in which thealignment posts align the cassette with the edges of the wall 124. Thedesired number of capsules to be counted is then entered via the keypad28, a patient prescription bottle is placed adjacent exit spout 21, anda start button on the keypad is activated. Operation of the start button(1) provides electricity to the electromagnet 88 to temporarily securethe cassette 16 thereon, (2) activates the solenoid 83 to open the gateportion 82 of the leaf spring 81 on the cassette, and (3) operates thevibration system 12 to initiate vibration of the cassette. Referring toFIGS. 3, 8, 10 and 14, when the cassette 16 is vibrated by the vibrationsystem 12, capsules 104 in the reservoir 44 of the cassette are moved inthe counterclockwise feed direction through the opening 52 and thenarrow 53 (it being appreciated that for purposes of clarity far fewercapsules than typically present are shown). The height H of the opening52 and size of the narrow 53 limits too many capsule from entering thetrack area 54 at one time as the opening height basically guaranteesthat the capsule will not exit the reservoir in a stacked configurationwhile the narrow limits the number of capsules simultaneously enteringthe track area. Referring to FIG. 14, the vibration urges capsules whichhave passed through the narrow 53 and into the track area 54 to movetoward the peripheral wall 48 and into the channel 66. Generally, thecapsules are provided in a quantity to substantially fill the reservoir44 and crowd the track area 54. The channel 66 is sized to receive thecapsules 104 in a lengthwise orientation. The capsules 104 continue inthe channel 66 in a counterclockwise movement through the exit guide 60and are directed single file toward the exit 58. The capsules fallthrough the exit 58, enter the chute 18, are each counted by the objectcounting system 22, and are dispensed at the spout 21 into a bottle(FIGS. 1 and 3). Capsules 104 which do not exit the cassette 16 during afirst pass around the track area 54 are guided back toward the narrow bythe return guide 62. The capsules 104 continue traveling around thetrack area 54 and through the exit 58 until the selected number ofcapsules is counted, as indicated by the display 26. Once the system hascounted the required number of capsules, the vibration stops, thesolenoid releases the gate, and the cassette is released from themounting assembly. With this system, objects can be fed and countedrelatively rapidly, typically from five to twenty per second.

According to a preferred aspect of the invention, when the system hascounted to near the required number, the vibration system vibrates at alower amplitude to slow down the rate of counting. This featuresubstantially prevents overcounts which may occur due to having countedthe required number of capsules even though uncounted capsules stillexist in the space between the exit hole 58 and the counting system 22.A slow down system is described in detail in co-owned U.S. Pat. No.5,473,703, which is hereby incorporated by reference herein in itsentirety.

A cassette can easily and rapidly be removed from the system by removingthe power to the electromagnet 88. The ball plungers 90 then push thecassette from over the electromagnet to facilitate manual removal of thecassette from the mounting assembly. A second cassette may then beplaced over the electromagnet and power can then be resupplied to theelectromagnet to provide a very secure coupling with the secondcassette.

It is noted that in cassette 16, all tablets must travel in single filethrough exit hole 58. As such, one limitation of the cassette system isthe speed at which tablets or other single dose medications can be fedand exited into the chute for counting. In view thereof, a secondembodiment of a cassette adapted to feed tablets more rapidly and yieldgreater system throughput is provided. Turning now to FIGS. 15, 16 and17, the second embodiment of the cassette 216 generally includes areservoir 244 which feeds tablets and other single dose medication totwo discrete trays (levels) 254, 255. Each tray is provided with an exithole 258, 259 which feeds the tablets into the chute 18 of the system10. More particularly, the cassette 216 includes a base 240 having anupper surface defining the first tray 254, an intermediate shelf 241having an upper surface defining the second tray 255, an annular coverover the shelf 243, and a cylindrical element 242 over the cover andwhich defines the reservoir portion 244. The base 240, as shown in FIG.16, is substantially similar to base 40 with the following exception: asecond hole 281, preferably walled-off from exit hole 258 and theremainder of the first tray 254, is provided preferably adjacent exithole 258. The second hole 281 is provided along the periphery of thetray and located counterclockwise from the exit hole 258. Referring toFIG. 17, the shelf 241 is also substantially similar to base 40 with thefollowing exceptions. First, exit hole 259 is aligned over the secondhole 281 on the first tray 254. Second, the shelf includes a relativelylarge central opening 283 adapted to permit tablets in the reservoir 244to pass therethrough and onto the first tray 254.

When tablets are provided into the reservoir, they naturally stacksubstantially in the formation shown in broken lines in FIG. 15. As thecassette is vibrated, tablets move from the stack onto the tray andshelf, and peripherally to the tracks 254, 255. From the tracks, thetablets are fed toward the exit holes 258, 259. Tablets exiting exithole 258 fall directly into the entrance 130 of the chute 18. Tabletsexiting exit hole 259 fall through hole 281 in the first tray and theninto the chute 18. In order to close the exit holes, two leaf springgates 291, 293 are used. Opening of the spring gates may be actuated bytwo solenoids provided in the housing 24, each being to adapted toseparately open one of the gates. Alternatively, a single solenoidconfigured to open both gates, e.g., having two arm portions coupledthereto, may be used to operate both gates. Where two solenoids areused, it may be preferable to have one of the solenoids operate torelease and close one of the gates when the number of counted tabletsapproaches the number desired, leaving only one of the gates open. Thisprevents two tablets from substantially simultaneously falling into thechute (one from each exit hole) when only one additional tablet isneeded for a full count.

As stated above, the dual sensor array of previously incorporated U.S.Pat. No. 5,768,327 is adapted to sense multiple objects simultaneouslyfalling passed the sensors. As such, it is ideally suited to sensetablets exiting from the two-level cassette.

A relatively larger storage capacity is also needed for certain highvolume medications dispensed, e.g., by a mail order pharmacy dealingwith high prescription volumes. A greater capacity is desired in orderto limit the number of times the cassette must be removed for refill.Turning now to FIGS. 18 through 20, a first relatively higher capacitycassette 400, preferably for use with tablets, is shown. The cassette400 includes a base 402, a circumferential side wall 404, and a lid 406.As discussed with previous embodiments, the base 402 is provided with anupstanding threaded stud 408, and the lid 406 includes a hole 410 whichis positioned over the top of the stud 408. A nut 412 may be thread overthe exposed portion 414 of the stud 408 to secure the lid 406 againstthe wall 404. The base 402, as also discussed with previous embodiments,includes an exit hole 416 and a releasable gate 418.

According to this embodiment, no large shelf (such as annular shelf 43),which limits the capacity of the cassette, is included in the cassette.Rather, the wall 404 is provided with a preferably annular top guide (alip) 420 about its inside periphery. The annular top guide 420 ispositioned preferably more than a height of a tablet above the base 402,but less than twice the height of a tablet, and preferably 1.2-1.8 timesthe height of tablet. The top guide 420 has a width of less than twicethe diameter of a tablet, and preferably less than 1.5 times thediameter. The height of a tablet is defined as the dimension transverseto the flattest surface of a tablet, while the diameter is the largestdimension, whether or not the tablet is round. The area under the topguide 420 defines a channel 436 which is substantially open along itsinternal periphery, with the exception of the location leading up toexit hole 416 (extending from a location clockwise of the exit hole 416toward the exit hole in cassettes adapted to be vibrated in acounterclockwise direction) which is enclosed by a barrier wall 422 suchthat a tunnel 426 leading to the exit hole is formed with an entrance428. A tablet guide 424 is provided on the base 402 clockwise of thebarrier wall 422. The tablet guide 424, having a height substantiallygreater than height of the top guide 420, and preferably more than halfthe height of the wall 404, is configured to direct a majority oftablets that are not located under the top guide 420 away from thelocation at which the annular guide wall starts; i.e., thecounterclockwise-most position of the barrier wall 422. The tablet guide424 has a preferably tapered leading edge 432 provided circumferentiallybefore the entrance 428 to the tunnel 426 and a terminal edge 434terminating circumferentially after the entrance 428.

In use, the cassette 400 is filled with tablets. When the cassette isvibrated counterclockwise, some of the tablets move around the wallunder the top guide 420 and toward the exit hole 416. As the tabletsmove around the base, the guide wall 424 directs some tablets away fromthe entrance 428 of the tunnel 426 to prevent tablet jamming at theentrance. The tunnel 426 forces the tablets entering therein to be in asingle file formation, without tablets stacking one on top of anotherwhich could otherwise jam the exit hole 416.

Turning now to FIGS. 21 through 24, a second relatively higher capacitycassette 500, preferably for use with capsules and caplets (hereinafter,collectively ‘capsules’), is shown. The cassette's base 502, side wall504, lid 506, exit hole 516 (FIG. 22) and gate 518 (FIG. 21) arepreferably configured and coupled as described above with respect tocassette 400.

According to this embodiment, a ramp 520 is provided about a portion ofthe inside periphery of the wall 504. The ramp 520 has a width (FIG. 22)less than 1.5 times the diameter of a capsule for which the cassette 500is intended. The ramp 520 rises from the base 502 in a counterclockwisedirection. At the highest rise of the ramp 520, approaching the exithole 516, a barrier 522 is provided to prevent capsules from beingcaught under the ramp. The barrier 522 is preferably lower than the rampsurface at that location. The exit hole 516 is provided with a cover 532to prevent capsules which are not directed up the ramp from fallingtherethrough. A guide 524, similar to tablet guide 424, is provided onthe base 502. The guide 524 intersects the ramp 520 at location 529 andthereby ensures that capsules can move up the ramp only in a lengthwisedirection; capsules otherwise oriented are removed from the ramp 520 bycontacting the guide 524.

In use, the cassette 500 is filled with capsules. When the cassette isvibrated counterclockwise, some of the capsules move against theperiphery of the wall and up the ramp 520 toward the exit hole 516.Capsules which do not properly fit on the ramp 520 fall off at theapproach to the exit hole. Capsules which are not on the ramp 520 movearound the base 502, and the guide wall 524 directs such capsules awayfrom a portion of the ramp 520 which approaches the exit hole 516. Thisprevents a layer of capsules from forming on the base 502 behind theguide wall 524. As such, the capsules reach the exit hole 516 in asingle file formation, without tablet stacking which could otherwise jamthe exit hole.

The above cassette embodiments permit rapid dispensing of medicationsstored in the cassettes. However, there may be medications in a pharmacywhich are used with an infrequency such that cassette storage is notwarranted. Therefore, turning now to FIGS. 25 and 26, according toanother aspect of the invention, the system 10 may be used as apour-through system. When a cassette 16, 216 is not located on themounting assembly and the shield 132 is removed from over the chuteentrance 130, a funnel 134 into which tablets may be poured is providedin the chute entrance. In this pass-through configuration, no presetnumber is entered prior to pouring tablets into the funnel. Rather,sensor 129 indicates that a cassette is not being used, and the system10 is automatically adapted to count tablets passing through the funnel.The number of tablets counted is displayed on the display 26.

Referring now to FIG. 27, according to another aspect of the invention,a universal bowl feeder 316 can be attached to and detached from themounting assembly 14, preferably in the same manner as the cassettes. Assuch, the bowl feeder 316 is made from metal or made from plastic andprovided with a metal insert or bottom plate, as described with respectto the cassettes. This enables the bottom 318 of the feeder 316 to bemounted to the mounting assembly 14. The feeder 316 has a reservoir 320which holds tablets, and a ramp 322 designed to feed practically anysize or shape tablet or other single dose medication. Bowl feeders withthis interior design are available from Kirby Lester Inc. of Stamford,Conn. Referring to FIGS. 4, 15 and 17, the bowl feeder 316 ispositionable within the recess 128 such that the sensor 129 causes thesystem to enter preset counting mode. A desired number of tablets isentered via the keypad 128, and a start button on the keypad is thenactuated causing the electromagnet of the mounting assembly 14 to securethe feeder 316 thereto, and the vibration system 16 to vibrate thefeeder to feed tablets from the reservoir 320, up a the ramp 322, and toan exit 324, where the tablets fall into the chute entrance 130 and arethen counted by the object counting system 22. The feeder accommodatesprescriptions which are not provided their own dedicated cassette, butfor which a pharmacist does not wish to manually feed tablets until adesired number of tablets is counted.

There have been described and illustrated herein embodiments of acassette system for feeding, counting, and dispensing tablets, capsules,caplets, and the like. While particular embodiments of the inventionhave been described, it is not intended that the invention be limitedthereto, as it is intended that the invention be as broad in scope asthe art will allow and that the specification be read likewise. Thus,while the system is described as being suitable for manual cassettecoupling and removal in a pharmacy setting, it will be appreciated thatthe system may be adapted for a robotic system in a pharmacy setting orotherwise. In addition, while an electromagnetic mounting assembly ispreferred, it will be appreciated that other rapid and easy to usecoupling systems may also be used. For example, a preferablypower-driven mechanical coupling which threadably secures the cassetteto the mounting assembly can be used. Further, while cassettes with oneand two track layers have been described, it will likewise beappreciated that cassettes with three or more track layers can similarlybe used to even more rapidly count tablets. Also, while the feeddirection is shown and described as being counterclockwise, it will beappreciated that the shakers can be configured to shake the cassettewith clockwise motion, and the guides, narrow, and, in one embodiment,two exit holes can be configured to guide tablets in the clockwisedirection toward the exits. Further, while particular opening height andnarrow dimensions relative to the tablet size were disclosed as beingpreferred, it will be appreciated that other dimensions could beutilized. Also, while the system is stated to secure the cassette and tothe mounting assembly upon activation of a start button, it will beappreciated that locking may occur based upon the sensor recognizing acassette or bowl feeder being placed on the mounting assembly. Inaddition, the release of the gate by the solenoid and the release of thecassette or bowl feeder from the mounting assembly may be triggered bymeans other than described. Furthermore, the funnel may be permanentlycoupled to the housing in a manner which permits placement and removalof a cassette in conjunction with the funnel. Also, the system mayinclude a two-layer cassette and have two separate feeds each having aone-dimensional optical system for sensing tablets passing through thefeeds, the feeds then going to a common chute or exit spout. It willtherefore be appreciated by those skilled in the art that yet othermodifications could be made to the provided invention without deviatingfrom its spirit and scope as claimed.

What is claimed is:
 1. A cassette for a system for feeding and countingdiscrete objects, said discrete objects having a height, said cassettecomprising: a) a substantially horizontal base including an exit hole;b) a peripheral wall defining a reservoir adapted to store a pluralityof discrete objects; and c) a structure about said internal peripheryadapted to feed the discrete objects single file toward said exit hole.2. A cassette according to claim 1, wherein: said structure is a lip,and said lip and said base together define a channel adapted to receivethe discrete objects in a single file.
 3. A cassette according to claim2, wherein: said lip is annular.
 4. A cassette according to claim 2,further comprising: d) a barrier wall provided against a portion of saidlip adjacent said exit hole, such that said exit hole is partiallyenclosed by said peripheral wall, said barrier wall, and said structure.5. A cassette according to claim 4, wherein: said peripheral wall, saidbarrier wall, and said structure define a tunnel through which saiddiscrete objects may be fed toward said exit hole.
 6. A cassetteaccording to claim 1, wherein: said structure is a ramp.
 7. A cassetteaccording to claim 1, further comprising: d) a guide provided on saidbase and extending higher than said structure.
 8. A cassette accordingto claim 7, wherein: said guide intersects said structure.
 9. A cassetteaccording to claim 7, wherein: said guide is separated from saidstructure.
 10. A cassette according to claim 7, wherein: said guideincludes a leading edge and a terminal edge, wherein said leading edgeis provided on one side of an entrance to said exit hole and saidterminal edge is provided on the other side of said entrance to saidexit hole.
 11. A cassette according to claim 10, wherein: said leadingedge is tapered.
 12. A cassette according to claim 1, furthercomprising: d) a plurality of discrete objects each having a fist width,wherein said structure has a second width less than 1.5 times said firstwidth.
 13. A cassette according to claim 12, wherein: said plurality ofdiscrete objects each has a first height, and said structure is a liplocated at a second height above the base which is less than twice saidfirst height, said discrete objects being movable beneath said lip. 14.A cassette for a system for feeding and counting discrete objects, saidcassette comprising: a) a substantially horizontal base including anexit hole; b) a peripheral wall about said base and having an internalperiphery, said base and said peripheral wall defining a reservoiradapted to store a plurality of discrete objects; and c) a lip aboutsaid internal periphery, said lip and said base defining a channel whichleads to said exit hole.
 15. A cassette according to claim 14, furthercomprising: d) a guide provided on said base and extending higher thansaid lip, said guide adapted to direct some discrete objects which arenot in said channel away from said exit hole.
 16. A cassette for asystem for feeding and counting discrete objects, said cassettecomprising: a) a substantially horizontal base including an exit hole;b) a peripheral wall about said base and having an internal periphery,said base and said peripheral wall defining a reservoir adapted to storea plurality of discrete objects; and c) a ramp extending up from saidbase and about said internal periphery adapted to feed the discreteobjects single file toward said exit hole.
 17. A cassette according toclaim 16, further comprising: d) a guide provided on said base andextending higher than said ramp, said guide adapted to direct somediscrete objects which are not on said ramp away from said exit hole.18. A cassette for a system for feeding and counting discrete objects,said discrete objects having a height, said cassette comprising: a) abase including an exit hole; b) a peripheral wall about said base andhaving an internal periphery, said base and said peripheral walldefining a reservoir adapted to store a plurality of discrete objects;and c) a structure about said internal periphery adapted to feed thediscrete objects single file toward said exit hole.
 19. A cassette for asystem for feeding and counting discrete objects, said discrete objectshaving a height, said cassette comprising: a) a substantially horizontalbase; b) a peripheral wall about said base and having an internalperiphery, said base and said peripheral wall defining a reservoiradapted to store a plurality of discrete objects; c) an exit for thediscrete objects; and d) a structure about said internal peripheryadapted to feed the discrete objects single file toward said exitopening.
 20. A cassette for a system for feeding and counting discreteobjects, said discrete objects having a height, said cassettecomprising: a) a base; b) a peripheral wall about said base and havingan internal periphery, said base and said peripheral wall defining areservoir adapted to store a plurality of discrete objects; c) an exitlocated at or adjacent said peripheral wall; d) a structure about saidinternal periphery adapted to feed the discrete objects single filetoward said exit; and e) a lid which is coupled to said peripheral walland encloses said reservoir.
 21. A cassette according to claim 20,wherein: said base is substantially planar.
 22. A cassette according toclaim 20, wherein: said exit is provided in said base.
 23. A cassetteaccording to claim 22, wherein: said base is substantially planar.
 24. Acassette according to claim 23, wherein: said base is substantiallyhorizontal.